Carrier Assembly with Fused Powder and Frame-Warp Aperture

ABSTRACT

A carrier assembly is provided for reinforcing vehicle flange engaging strip such as a weatherstrip or trim strip. The carrier assembly includes a serpentine frame and a warp interlaced with the frame to form at least one frame-warp aperture. A fused powder bonds to at least one of the serpentine frame and the warp and inhibits movement of the warp relative to the frame, substantially preserving the frame-warp aperture.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Division of U.S. application Ser. No. 11/054,485,filed Feb. 9, 2005, entitled Carrier Assembly with Fused Powder andFrame-Warp Aperture and is expressly incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A “SEQUENCE LISTING”

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a carrier assembly for reinforcement ofa vehicular strip such as a finishing strip, a trim strip or a sealingstrip. More particularly, the present invention relates to a carrierassembly having a serpentine frame, a warp connected to the frame so asto define a frame-warp aperture, wherein movement of the warp relativeto the serpentine frame is inhibited by a fused powder on at least oneof the frame and the warp, and at least a substantial portion of theframe-warp aperture is preserved.

2. Description of Related Art

Wire carriers are used as a reinforcing frame for extrusion products,such as motor vehicle strips. The wire carriers typically include acontinuous wire weft formed into a zig-zag shape with warp threads onthe limbs. During manufacture of the motor vehicle strips, the wirecarrier is passed through an extruder and is thus subjected to stressesand temperatures which can cause the warp threads to drift laterally,stretch longitudinally and degenerate. Such processing of the wirecarrier can result, for example, in breakage of the warps and distortionof the wire carrier which affects the subsequent extrusion process andleads to reduced quality and performance of the resulting vehicularstrip. In the forming and extrusion processes, drifting of the warpthreads can cause air bubbles and exposure of the wire in the finalproduct. In addition, the shifting of the warp threads can lead tounbalanced locations of the warp threads in the resulting vehicularstrip, which can lead to the strip “laying over” upon installation on avehicle.

In addition, movement of the warp threads during the extrusion processcan impart a spiral to the resulting vehicular strip. The tendency ofthe vehicular strip to spiral significantly hinders installation of thestrip on a vehicle. Further, unintended redistribution of the warpthreads can lead to a “hungry horse” appearance in the resulting stripas the wire produces corresponding surface features.

There has long been a need to develop a stable wire carrier whichovercomes these problems and many attempts have been made withoutcomplete success.

EP 0384613 discloses a knitted wire carrier in which stitched warpthreads comprise two threads of polymeric material having differentmelting points such that when the melting point of the lower meltingthread is exceeded the melted thread causes the other thread to beattached to the wire weft. This structure allows single strands of warpthread plied with a meltable filament to be bonded to the wire carrierwherever they are knitted.

U.S. Pat. No. 5,416,961 to Vinay discloses a knitted wire carriercomprising at least one meltable filament laid-in into at least twoadjacent warp threads, whereby on heating, the melted filament causesthe at least two adjacent warp threads to be bonded to the wire and/orto each other for stabilizing the resulting wire carrier against warpdrift.

In spite of these issues, the wire carrier provides substantialbenefits. Specifically, the wire carrier exhibits an inherentflexibility about three axes, which in turn provides good handlingcharacteristics of the finished product. Further, in contrast to manystamped metal and lanced and stretched metal carriers, the wire carrieris able to bear relatively high loading, particularly during theextrusion process. In addition, the wire carrier has the benefit ofwithstanding greater flexing without exhibiting metal fatigue.

Thus, there is a need to develop a stable wire carrier for extruded andmolded polymeric products. The need also exists for a carrier assemblywith reduced or negligible warp drift, thereby overcoming the problemsassociated with warp drift.

BRIEF SUMMARY OF THE INVENTION

The present invention encompasses a carrier assembly with stable andpredictable warp locations which provide improved consistency andquality of the carrier assembly and hence improved consistency andquality of any subsequent vehicular strip which incorporates the carrierassembly.

The carrier assembly includes a serpentine frame, a warp extending alongthe frame, wherein the warp and the serpentine frame define a frame-warpaperture, and a fused powder on at least a portion of one of the frameand the warp. The fused powder impedes movement of the warp relative tothe frame and preserves at least a substantial portion of the frame-warpaperture.

The fused powder can be located at a junction of the frame and the warp.In an alternative configuration, the fused powder can be locatedprimarily on the frame. In a further configuration, the fused powder canencapsulate at least a portion of the frame and the warp. In eachconfiguration, at least a substantial portion of the frame-warp apertureis preserved.

In selected configurations, the serpentine frame is formed from ametallic or polymeric material and defines a plurality of limbsinterconnected at alternate ends by connecting regions. The warp caninclude a single or a plurality of threads or yarns interlaced with thelimbs of the serpentine frame to define frame-warp apertures.

The fused powder is readily deposited on the serpentine frame and thewarp and can be fused to inhibit movement of the warp relative to theframe, and particularly inhibit movement of the warp transverse to alongitudinal dimension of the frame while preserving the frame-warpaperture.

The carrier assembly can be formed by powder coating the serpentineframe and an interlaced warp, interlacing the warp on a powder coatedserpentine frame or interlacing a powder coated warp with the serpentineframe.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 is a top plan view of a representative carrier assembly.

FIG. 2 is a cross-sectional view of a vehicular weather stripincorporating a configuration of the carrier assembly.

FIG. 3 is a top plan view of the serpentine frame having parallel limbs.

FIG. 4 is a top plan view of the serpentine frame having curvilinearlimbs and connecting regions.

FIG. 5 is a top plan view of the serpentine frame having taperedconnecting regions.

FIG. 6 is a top plan view of the serpentine frame having faceted limbsand curvilinear connecting regions.

FIG. 7 is a top plan view of the serpentine frame having a firstconnecting region configuration along one edge of the frame and adifferent second connecting region configuration along a second edge ofthe frame.

FIG. 8 is a top plan view of the serpentine frame having parallel limbsand a plurality warps interlaced with the frame.

FIG. 9 as a top plan view of the serpentine frame having curvilinearshaped limbs and a plurality of warps interlaced with the frame.

FIG. 10 as a top plan view of the serpentine frame having curvilinearshaped limbs and a different configuration of warps interlaced with theframe.

FIG. 11 is an enlarged cross-sectional schematic view showing the fusedpowder encapsulating a portion of the serpentine frame and the warp.

FIG. 12 is a schematic cross-sectional view of a fused powder on aportion of the serpentine frame engaging a warp.

DETAILED DESCRIPTION OF THE INVENTION

A carrier assembly 10 in accordance with the present invention is shownin FIG. 1. The carrier assembly 10 includes a serpentine frame 20, atleast one warp 40 and a fused powder 60 on at least one of the frame andthe warp to define at least one frame-warp aperture 30.

Referring to FIG. 2, the carrier assembly 10 can be incorporated intoany of a variety of motor vehicle finishing strips, trim strips orweather strips. A vehicular weatherstrip 12 embedding the carrierassembly 10 is shown in FIG. 2. It is understood the vehicle strips canhave any of a variety of configurations for engaging a vehicle, such asa flange engaging strip.

Serpentine Frame

The serpentine frame 20 has a plurality of transversely extending limbs22 interconnected at alternate ends by connecting regions 24. The limbs22 can be straight or curvilinear, and can define sections that arelinear, faceted, banana shaped, propeller shaped or any combinationthereof. The limbs 22 are in a generally parallel relationship, such asadjacent limbs of FIGS. 1, 3 and 8, or alternating limbs are parallel asshown in FIGS. 4-7 and 9-10. The serpentine frame 20 has a width definedby the connecting regions 24 at the end of the limbs 22.

The serpentine frame 20 can be described in terms of the number of limbs22 per inch (cm) and the length of the limbs. A range for limbs per inch(limbs per cm) is typically from approximately 4 to 12 limbs per inch(1.6 to 4.7 limbs per cm), with a usual range of about 7 to 10 limbs perinch (2.8 to 3.9 limbs per cm), and typical lengths of the limbs (acrossa width of the carrier assembly 10) range from approximately 0.5 inches(1.3 cm) to approximately 3 inches (7.6 cm).

Although the term “serpentine” frame 20 is used, the serpentine frame isintended to encompass any frame construction, wherein the limbs 22 andconnecting regions 24 can have any of a variety of configurationsincluding but not limited to, linear, curvilinear or faceted, wherein alongitudinal dimension of the frame extends generally transverse to thelimbs.

The serpentine frame 20 is formed of a filament, or a plurality offilaments having sufficient resiliency to accommodate repeated flexingwhile having sufficient strength for the filament to retain a downstreamformed shape, such as a U-shape transverse to the longitudinal dimensionof the serpentine frame. The serpentine frame 20 can be formed of ametallic or non metallic filament. The non metallic filament materialsinclude, but are not limited to plastics, elastomers, polymerics,ceramics or composites. Metallic filament materials include but are notlimited to wires, alloys, steel, stainless steel, aluminum, galvanizedmetals, as well as composites.

For purposes of description, the serpentine frame 20 is set forth interms of a metallic filament such as wire. However, it is understood,the description is applicable to any type of filament forming theserpentine frame 20.

The thickness of the wire is at least partially determined by theintended operating environment of the resulting strip as well as theconfiguration of the available extrusion tooling. Typically, the wirehas a generally circular cross-section. However, it is understood thewire may have any of a variety of cross-sectional profiles, such as butnot limited to obround, elliptical, faceted or triangular.

In one configuration of the wire, the wire has a diameter betweenapproximately 0.010 inches (0.25 mm) and 0.050 inches (1.3 mm), whereina further construction of the wire has a diameter of approximately 0.018inches (0.46 mm) to 0.035 inches (0.89 mm). In yet another construction,the wire is a low carbon steel wire or 301 stainless steel having adiameter of about 0.030 inches (0.76 mm).

Referring to FIGS. 1 and 8-10, the warp 40 extends along thelongitudinal dimension of the serpentine frame 20. The warp 40 caninclude a single strand or thread, or multiple strands or threads whichcan be separate or intertwined. The term “warp” is intended to encompasseach of these configurations.

The warp 40 can be secured to the serpentine frame 20 by interlacing,which includes but is not limited to knitting or stitching such ascrocheting, sewing, weaving or threading. Referring to FIGS. 1 and 8-10,the frame 20 and the warp 40 define a plurality of frame-warp apertures30. The frame-warp apertures 30 have a periphery defined by the frame 20and the warp 40. Depending upon the interlacing of the warp 40 and theframe 20, and the number of warps, the frame-warp apertures 30 can havea variety of sizes. Similarly, there can be a range in the number offrame-warp apertures 30 as defined by the number of limbs 22 per inch(cm), the number of warps 40 and the interlacing configuration.

In one configuration, the warp 40 encompass a portion of the serpentineframe 20 within a crocheted stitch. The warp 40 can be secured to theserpentine frame 20, such as with chain stitching and the warp ispre-tensioned, for example, from approximately 0.5 to 1.0 pounds (0.22to 0.45 Kg) per warp end, with a satisfactory pre-tensioning ofapproximately 0.7 pounds (0.32 Kg). It is understood the stitching shownin FIGS. 1 and 8-10, is representative and that the warp 40 can engagethe serpentine frame 20 by any of a variety of constructions.

Depending upon the interlacing of the warp 40 with the serpentine frame20, intra-warp aperture 35 can also be formed as seen in FIG. 1. Theintra-warp aperture 35 is defined by the warp 40, rather than the warpand the serpentine frame 20.

The warp 40 can be threads strands, or yarns of any of a variety ofmaterials, such as polymeric materials. The term polymeric is intendedto encompass a polymer based on organic or organo-silicone chemistry.The polymer can be a synthetic resin or a natural fiber, such as cotton.Synthetic resins are advantageously more durable and resistant to,although not free from, the stresses incurred during embedding, forexample during extrusion of the vehicular strip. Suitable polymericmaterials for the warp 40 include, for example polyesters,polypropylenes and nylons, with polyesters being satisfactory. The warpthreads have a typical size of about 400 to about 3,000 denier, with ausual size between approximately 800 denier to approximately 2,000denier.

The fused powder 60 is located on, and bonded to at least one of theserpentine frame 20 and the warp 40. The fused powder 60 impedes orinhibits movement of the warp 40 relative to the serpentine frame 20(along the transverse direction), thereby reducing warp drift, withoutthe fused powder occluding the frame-warp aperture 30. In oneconfiguration, the fused powder 60 constrains the warp 40 relative tothe serpentine frame 20. The resistance to movement of the warp 40relative to the serpentine frame 20 is created by contact between thewarp and the fused powder 60. It is believed the contact between thewarp 40 and the fused powder 60 can be created by the fused powderbonding to the serpentine frame 20, the fused powder bonding to thewarp, or the fused powder bonding the warp to the serpentine frame.

The amount of contact between the fused powder 60 and the warp 40 issufficient to reduce or retard movement of the warp relative to theserpentine frame 20, and particularly movement of the warp along alength of the limb 22. The contact between the fused powder 60 and thewarp 40 can be provided by the fused powder substantially encapsulatingthe serpentine frame 20 and the warp 40. Alternatively, the fused powder60 can be bonded to the serpentine frame 20, such as before the warp 40is interlaced, and thus contact the warp upon interlacing. It is alsocontemplated the fused powder 60 can be primarily bonded to the warp 40.

In one configuration, the fused powder 60 is on both the warp 40 and theserpentine frame 20 and effectively locks the warp to a position on theframe. The amount of fused powder 60 can range from the encapsulation ofat least a portion of one of the serpentine frame 20 and the warp 40seen in FIG. 11, to a discontinuous (broken) sputtering seen in FIG. 12.In all configurations, the amount of fused powder 60 is selected tosubstantially preserve the frame-warp aperture 30.

It is also contemplated the fused powder 60 can be initially located onone of the serpentine frame 20 or the warp 40, and subsequently remeltedafter interlacing the warp and the frame, so as to bond to both the warpand the frame.

In each configuration of the carrier assembly 10, including theconfiguration of the fused powder 60 encapsulating at least one of theserpentine frame 20 and the warp 40, at least a percentage of the totalnumber of frame-warp apertures 30 is preserved. That is, the fusedpowder 60 coats the exposed surfaces of the serpentine frame 20 and thewarp 40, without occluding all the frame-warp apertures 30. Typically,at least 50% to 100% of the original number of frame-warp apertures 30is preserved. It is understood certain configurations of the carrierassembly 10 can preserve as few as 10% of the total number of frame-warpapertures 30. That is, some of the frame-warp apertures 30 can beoccluded by the fused powder 60, without blocking all the apertures. Theinitial area of a given frame-warp aperture 30 and the amount of fusedpowder 60 are factors in determining the percentage of the originalframe-warp apertures 30 that remain after application of the fusedpowder 60.

Thus, the fused powder 60 can form a portion of the surface of theserpentine frame 20 or of the serpentine frame and the warp 40, whereinat least one frame-warp aperture 30 is substantially preserved. In theencapsulation configuration for a given frame-warp aperture 30, thefused powder 60 slightly extends into the frame-warp aperture, andoccludes a portion of the aperture. Typically, at least 80% of theoriginal area of the frame-warp apertures 30 in the carrier assembly 10is preserved, with configurations of the carrier assembly 10 preserving10% to 100% of the original area of the apertures. However, dependingupon the initial area of the frame-warp aperture 30 and the amount offused powder 60, a given aperture (or apertures of a certain area orsmaller) can be occluded. In such configuration, the remainingframe-warp apertures 30 are of a sufficient area to preclude occlusion,thereby preserving at least one frame-warp aperture.

In a further configuration, the fused powder 60 is bonded to primarilythe serpentine frame 20, with a minimal or insignificant amount ofpowder bonded to the warp 40. In this configuration, the fused powder 60forms a rough surface on the serpentine frame 20, as seen in FIG. 12,and does not encapsulate the frame, but rather forms localdiscontinuities or areas of fused powder. The roughness imparted by thefused powder 60 is sufficient to inhibit or impede lateral movement ofthe warp 40 relative to the serpentine frame 20 and limb 22. Typically,such roughness is less than the diameter of the warp 40. Thus, forexample, the fused powder 60 can create a surface roughness on the orderof approximately 0.001 inches (0.0025 cm) to 0.010 inches (0.0254 cm).In this configuration, the fused powder 60 preserves a majority of theframe-warp apertures 30, and in certain constructions maintains over 90%of the total number of frame-warp apertures 30 and over 90% of theinitial area of the frame-warp apertures of the carrier assembly 10.

Thus, a percentage of the total number of initial frame-warp apertures30 and a percentage of the initial total area of the frame-warpapertures are preserved. Depending upon the configuration of theserpentine frame 20, the warp 40 and the fused powder 60, any of avariety of combinations of preserved number of frame-warp apertures 30or preserved area of the frame-warp apertures can be provided.

Powders

The fused powder 60 can be a thermoplastic or thermoset. Thethermoplastic powders do not chemically react in a heat phase, butrather soften and then re-solidify upon reduction of the temperature.Thermoset powders are applied and then cured, inducing a chemicalcross-linking, thereby changing the fused powder 60 into a form thatwill not remelt.

The powders to be fused can be formulated to meet a variety ofperformance characteristics, including thickness, texture, color,hardness, chemical resistance, UV resistance or temperature resistance.The particle size of the powder can also be controlled in response tothe desired performance of the fused powder 60.

A representative thermoplastic powder is polyethylene, having a meltingpoint below a melting point of the serpentine frame 20 and the warp 40.In one configuration, the thermoplastic powder has a melting point ofapproximately 120° C.

A thermoset powder includes a thermosetting resin and a curing, or crosslinking agent. A thermosetting resin for the fused powder can includeepoxy resins, acrylic resins, phenol resins and polyester resins. Thesethermosetting resins can be used alone, or combined together with otherresins. In particular, a thermosetting resin having an epoxy group (thatis, glycidyl group), such as epoxy resins, acrylic resins are available.These thermosetting resins have excellent reactivity to a curing agent,even at relatively low temperatures, for example, approximately 120° C.

A latent curing agent such as dicyandiamide, imidazolines, hydrazines,acid anhydrides, blocked isocyanates, and dibasic acids can be added tothe resin particles as a curing promoter. The latent curing agent istypically stable at room temperature, and crosslinks with athermosetting resin in a range of 140° C. to 260° C. It is understoodany of a variety of cross-linking agents can be employed.

For thermoplastic or thermoset powders, an additive or a functionalmaterial can be added to the resin particles, such as a filler includingcalcium carbonate, barium sulfate or talc; a thickener, for examplesilica, alumina or aluminum hydroxide; a pigment including titaniumoxide, carbon black, iron oxide, copper phthalocyanine, azo pigments orcondensed polycyclic pigments; a flowing agent such as silicone oracrylic oligomer, for example butyl polyacrylate; an accelerating agentsuch as zinc compounds; a wax such as polyolefin; a coupling agentincluding silane coupling; an antioxidant; or even an antimicrobialagent.

Suitable powders to be fused are sold by Morton Powder Coating ofWarsaw, Ind. and include DG-5001 CORVEL® BLUE (ethylene/Acrylic),DG-7001 CORVEL® BLACK 20 (Ethylene/Acrylic), 78-7001 CORVEL® BLACK(Nylon) and 70-2006 CORVEL® YELLOW (Nylon).

It is also contemplated the fused powder 60 can be selected to promotebonding with the embedding material of the subsequent vehicular strip12. In such configurations, the powder includes a methacrylate coagentor a maleate.

Thus, the fused powder 60 can be constructed to retain the warp 40relative to the serpentine frame 20, preserve the frame-warp aperture30, bond to the embedding material of the vehicular strip 12 andinsulate the frame.

The fused powder 60 is formed by retaining unfused powder on one of theserpentine frame 20 and the warp 40, and then fusing the powder. Thepowder can be temporarily disposed on the one of the serpentine frame 20and the warp 40 by a variety of mechanisms including bonding agents,friction adhesion, or electrostatic attraction.

The bonding agents can be incorporated into the powder, or applied tothe one of the serpentine frame 20 and the warp 40 in a desired locationfor the fused powder 60 prior to exposure of the frame and the warp tothe powder.

Alternatively, a surface charge is formed on the one of the serpentineframe 20 and the warp 40, and the powder is oppositely charged, suchthat upon exposure of the oppositely charged powder to the surfacecharged portions of one of the frame and the warp, the powder istemporarily adhered.

To form the necessary surface charge on the one of the serpentine frame20 and the warp 40, a potential is applied to the frame. It has beenfound that a sufficient potential can be applied to the serpentine frame20 to create a charge sufficient to retain the powder prior to fusing.

By controlling the amount of powder exposed to the electrical potentialdifference between the powder and the surface charge on the one of theserpentine frame 20 and the warp 40, the amount of powder retained onthe one of the serpentine frame 20 and the warp 40 can be controlled. Asthe amount of retained powder on the one of the serpentine frame 20 andthe warp 40 at least partially determines the thickness of the fusedpowder 60, the thickness of the fused powder can thus be controlled.

Alternatively, the serpentine frame 20 and the warp 40 can be passedthrough a bath, or fluidized bed of the powder to deposit the powder onthe frame and the warp. The powdered serpentine frame 20 and warp 40 canthen be subject to a controlled vibration or air jet to remove excesspowder. Alternatively, the powder can be vibrated with the serpentineframe 20 and the warp 40 to deposit the powder. It is furthercontemplated that rollers can be used to deposit the powder on theserpentine frame 20 and the warp 40.

Further mechanisms for depositing the powder onto the serpentine frame20 and the warp 40 include sprinkling the powder onto the frame and thewarp, or passing the frame and the warp through a curtain of the powder.It is also contemplated the powder can be sprayed onto the serpentineframe 20 and the warp 40. The spray method can also involve imparting acharge to the powder, which is then electrostatically attracted to oneof the serpentine frame 20 and the warp 40. Alternatively, a contactdevice, such as a roller can also be employed to deposit the powder ontothe frame 20 and the warp 40.

The temporarily retained or adhered powder is then melted and bonded tothe serpentine frame 20 by a variety of options including radiative,convective, inductive or conductive heating. The bonding of the fusedpowder 60 to the serpentine frame 20 or the warp 40 is sufficient toinhibit movement of the warp relative to the limb 22.

The heating can be accomplished in a processing line downstream of theknitter (which formed the interlaced warp 40 and the serpentine frame20) and a finished carrier assembly 10 take-up apparatus. Heating abovethe melting point of the meltable (or curable) powder causes the powderto bond to the serpentine frame 20 and/or the warp 40. On cooling, themelted powder hardens and the warp 40 is bonded in position. In oneconfiguration, the warp 40 is bonded to the serpentine frame 20 andlocked in a given position. In a different configuration, the fusedpowder 60 forms the roughened surface on the serpentine frame 20 whichengage the warp 40. The carrier assembly 10 has a flat profile, islongitudinally stable and is virtually free of warp drift.

Heating of the frame, the warp and the powder can be accomplished by avariety of methods which allow the powder to be heated close to or abovethe melting point of the powder. In one configuration, the heating abovethe melting point of the meltable powder is carried out for a period oftime sufficient to cause the melted powder to at least partially flowabout the junction of the warp 40 and the serpentine frame 20.Generally, the heating of the serpentine frame 20, the warp 40 and thepowder can be accomplished by conductive, inductive, convective orradiative heating such as infrared, hot air or microwave. One method ofheating includes exposing the serpentine frame 20, the warp 40 and thepowder to a flow of heated air in an oven to fuse the powder withoutfusing or melting the warp. Another method comprises heating theserpentine frame 20, the warp 40 and the powder with infra-redradiation. A further method comprises passing the serpentine frame 20,the warp 40 and the powder over a heated roller. Another methodcontemplates induction heating of the serpentine frame 20. In yetanother configuration, the heated serpentine frame 20, the warp 40 andthe powder are passed between forming rolls. The roll treatment can alsohelp to maintain the flat profile of the carrier assembly 10. The rollforming treatment can be applied during the heating process orimmediately after the powder is fused.

Cooling of the carrier assembly 10 is accomplished by exposure tocooling jets or streams which can include air jets or ambienttemperatures for a period of time after pulling the carrier assemblyfrom the heater.

In contrast to powder coating the serpentine frame 20 interlaced withthe warp 40, it is contemplated the fused powder 60 can be bonded to thefilament prior to interlacing the warp 40. That is, the fused powder 60is bonded to the filament, and the coated filament is formed into theserpentine frame and interlaced with the warp 40. The fused powder 60thus mechanically engages the warp 40 and bonds to the serpentine frame20.

In a further configuration, it is contemplated the fused powder 60 canbe bonded to the warp 40 prior to interlacing with the filament.

Therefore, the process can include powder coating the serpentine frame20 and the interlaced warp 40, interlacing the warp with a powder coatedserpentine frame or interlacing a powder coated warp with the serpentineframe.

It is further contemplated that for thermoplastic fused powders 60 onone of the filament or the warp 40 prior to interlacing, the fusedpowder can be reheated after interlacing to induce the powder to fusebond to the remaining component.

The invention provides a strong, physically and chemically stablecarrier assembly 10, essentially free of warp drift which allows closegrouping and selective positioning of adjacent warp 40, and allowsgrouping and bonding of different numbers of adjacent warps. Warp damageis minimized in the subsequent extrusion coating processes and, overall,greater control of the profile, appearance and quality of the product isachieved. The present process uses existing knitting equipment with aminimum of modification and is effective in reducing manufacturingcosts.

It is also contemplated the amount of fused powder 60 can be selected toreduce or minimize de-spragging of the carrier assembly 10. That is,absent the fused powder 60, upon cutting the serpentine frame 20, thefree end of the serpentine frame 20 (the filament) tends to straightenand can form an undesirable projection which can interfere withsubsequent operator and machine handling of the carrier assembly 10. Itis believed the fused powder 60 can provide sufficient retentive forceon the carrier assembly 10 to substantially preclude the free end of theserpentine frame 20 (the filament) pulling from the warp 40. Thus, thepreviously required step of de-spragging the cut carrier assembly 10 isobviated.

In addition, it is believed the fused powder 60 on the warp 40 reduces atendency of the warp to fluff or fray upon the carrier assembly 10 (andthe warp) being cut to length. Reducing the fluff of the cut warp 40reduces the tendency of the carrier assembly 10 (and the warp) to absorbmoisture, and improves subsequent embedding of the carrier assembly,thereby providing a more satisfactory finished product.

The carrier assembly 10 is particularly useful as reinforcement forelastomeric (polymeric) vehicular strip 12 for example, flange engagingstrips including trunk seals, door seals or edge protector strips aswell as glass run channels, and sun roof seals. The carrier assembly 10is advantageous for extrusion processes due to the control or virtualabsence of warp drift and longitudinal stability under the conditions ofthe extrusion process. The carrier assembly 10 provides for positioningof the warp 40 or warps, at the parts of the strip requiring the mostreinforcement, for example, the base or the sides of a subsequentlyformed U-shape channel.

In subsequent formation of the vehicular strip 12 the preservedframe-warp aperture 30 is filled by the embedding material of the stripduring a conventional extrusion or molding processes. The materialembedding the carrier assembly 10 is typically a polymeric material,such as for example, a thermoplastic or thermosetting elastomer.Generally, the carrier assembly 10 is fed through an extruder, wherein apolymeric material is extruded about the carrier assembly 10 so as toembed the carrier assembly within the polymeric material. To providesatisfactory embedding of the carrier assembly 10, the embeddingmaterial must “strike through” the frame-warp aperture 30. That is, theembedding material must flow through the frame-warp aperture 30, therebyentirely embedding the cross section of the carrier assembly 10.

While the invention has been described in conjunction with specificembodiments thereof, it is evident that many alternatives,modifications, and variations will be apparent to those skilled in theart in light of the foregoing description. Accordingly, the presentinvention is intended to embrace all such alternatives, modifications,and variations as fall within the spirit and broad scope of the appendedclaims.

1. A method of forming a carrier assembly, the method comprising fusinga powder to at least one of a serpentine frame and a warp to inhibitmovement of the warp relative to the frame and substantially preserve aframe-warp aperture.
 2. The method of claim 1, further comprisingembedding the fused powder frame and warp in a strip material tosubstantially fill the frame-warp aperture.
 3. The method of claim 1,further comprising employing a flowable material as the powder.
 4. Themethod of claim 1, further comprising employing a particulate materialas the powder.
 5. The method of claim 1, further comprising interlacingthe warp to the frame.
 6. The method of claim 1, further comprisingknitting the warp to the frame.
 7. The method of claim 1, furthercomprising weaving the warp to the frame.
 8. The method of claim 1,further comprising crocheting the warp to the frame.
 9. The method ofclaim 1, further comprising heat fusing the powder to a junction of theframe and the warp.
 10. The method of claim 1, further comprising fusinga sufficient amount of powder to at least partially coat the frame andthe warp.
 11. The method of claim 1, further comprising forming theframe with a plurality of limbs interconnected at alternate ends byconnecting regions, and the warp extends transverse to the limbs along alongitudinal dimension of the serpentine frame.
 12. The method of claim11, further comprising forming the interconnecting regions as linear.13. The method of claim 11, further comprising forming theinterconnecting regions as curvilinear.
 14. The method of claim 11,further comprising forming the interconnecting regions as segmented. 15.The method of claim 11, further comprising forming the limbs to includean inflection point.
 16. The method of claim 11, further comprisingforming the limbs to be linear.
 17. The method of claim 11, furthercomprising forming the limbs to be curvilinear.
 18. The method of claim1, further comprising forming the powder of one of a thermoplastic and athermoset.
 19. The method of claim 1, further comprising fusing thepowder to form a discontinuous surface on the serpentine frame.
 20. Themethod of claim 1, further comprising fusing the powder to form adiscontinuous surface on the warp.